Hyster's 241-page S1.0E service manual PDF (OEM ID 4197722) takes the S1.0E, S1.2E and S2.4HBE tiller forklifts from battery installation and voltage setting through mast chain replacement and electromagnetic brake adjustment. Wiring diagrams trace the tiller board, module connectors and battery charger circuits, while hydraulic schematics lay out the lift pump, pressure control valves and directional valves. Diagnosis gets its own chapter. The Tester menu and alarm troubleshooting tables sit next to electrical component measurements and motor insulation checks. Measure the solenoid valve coil against its 5.6 Ohm figure and the electromagnetic brake coil against 15 Ohm. If your job is renewing a hydraulic pipe or cylinder gaskets, the schematics show how each line connects to the lift pump and valves. A searchable text layer and bookmarked chapters take you straight to the reducer, the drive motor or the scheduled maintenance tables, so you can name the right assembly before ordering.
What's Inside This Hyster S1.0E, S1.2E, S2.4HBE Manual
| System | Pages | Key Topics |
|---|---|---|
| Technical Information | 1-3 | Truck Models, Service Network, Manual Purpose |
| General Safety Rules | 4-12 | Personal Safety, Workplace Safety, Battery Safety, Suspension Elements, Welding Safety |
| Presentation | 13-23 | Truck Presentation, Views of the Truck, Truck Identification Data and Load Capacities (Truck Identification Data Plate, Load Capacity Data Plate, Truck Punching) |
| Installation and Settings | 24-36 | Truck Unloading, Oil Reservoir, Battery Installation, Battery Voltage Setting, Truck Usage Conditions |
| Diagnostics and Measurements | 37-64 | Module Connectors, Tester Menu, Alarm Troubleshooting, Electrical Component Measurements, Motor Insulation |
| Electrical System | 65-125 | Wiring Diagrams, Tiller Board, Battery Status Led, Truck Functions, Module Parameters, Battery Charger |
| Hydraulic System | 126-169 | Hydraulic Functions, Pressure Control Valves, Directional Valves, Lift Pump, Hydraulic Pipes, Cylinder Gaskets |
| Basic Truck Mechanics | 170-199 | Traction Wheel, Castor Wheel Assembly, Load Wheels, Tiller, Drive Motor |
| Mast Assembly Mechanics | 200-221 | Mast Characteristics, Mast Assembly Components, Fork Small Mast, Chain Replacement, Bearing Replacement |
| Reducer | 222-227 | Reduction Unit Components, Reduction Unit Removal, Reduction Unit Disassembly |
| Braking System | 228-233 | Electromagnetic Brake Components, Operation, Braking Systems, Electromagnetic Brake Dismantling, Electromagnetic Brake Adjustment |
| Routine Maintenance | 234-241 | Warnings, Lubricants, Cleaning Products, Scheduled Maintenance |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Torque setting for M3 screw (Class 8) | 4 Nm | p. 8 |
| Torque setting for M3 screw (Class 10) | 5.2 Nm | p. 8 |
| Solenoid valve coil resistance | 5.6 Ohm | p. 63 |
| Electromagnetic brake coil resistance | 15 Ohm | p. 63 |
| Inverter maximum current (24V) | 165A (RMS) for 2' | p. 102 |
| Output direct current (24V) | 70A (RMS) continua. | p. 102 |
| Fixing screws of the Q_D valve torque | 45 Nm | p. 138 |
| Castor wheel screw torque | 60 Nm | p. 177 |
| Castor wheel screw torque | 60 Nm | p. 177 |
| Castor wheel to truck screws torque | 51-56 Nm | p. 177 |
| Maximum air pressure for cleaning | 1 bar | p. 4 |
| Drive motor power (S2 60 minutes) | 1.2 kW | p. 21 |
Hyster S1.0E, S1.2E, S2.4HBE Common Problems This Manual Covers
Hyster S1.0E/S1.2E tiller truck BATTERY LOW alarm 66 still showing on display after a full charge
Charge the battery first. If alarm 66 stays on, measure battery voltage with a voltmeter and compare it to the VOLTAGE BATTERY parameter, per page 48. The alarm trips at or below 10% of full charge. Adjust the ADJUST BATTERY function if the readings disagree. Never check charge with jumpers across the terminals (page 5). If the alarm persists, replace the module.
Manual Section: Combi Module Node 2 Master Alarms p. 48LOGIC FAILURE #1 alarm 19 appearing during traction acceleration or right when the brake releases
Check battery charge and power supply cabling when the alarm shows during acceleration, since page 46 points to undervoltage. If it trips as the brake releases, inspect the remote-control switch contacts and supply cabling. The module flags above 35V or below 9.5V. Disconnect the battery before working on the electrical system (page 5). If it appears at every key ON with stable voltage, replace the module.
Manual Section: Combi Module Node 2 Master Alarms p. 46Main remote-control switch not closing at key ON with CONTACTOR OPEN 38 or CONTACTOR CLOSED 37 displayed
Check the remote-control switch coil cabling for interrupted or disconnected wires, per page 47, and inspect the power contacts. Replace the remote-control switch if the contacts fail. Disconnect the battery first (page 5) and discharge the capacitors before working in the electric compartment (page 235). Never file or lubricate the contactor contacts; they can stick and cause loss of control.
Manual Section: Combi Module Node 2 Master Alarms p. 47Traction stopped with INCORRECT START 79 or FORW + BACK 80 alarm on the display
Use the TESTER menu to find an active traction request at start up, following page 48. Check the wire harness and microswitches, and confirm forward and backward requests are not active at the same time. Rule out an operator start sequence error. Disconnect the battery before harness work (page 5). If no malfunction turns up, replace the module.
Manual Section: Combi Module Node 2 Master Alarms p. 48Truck will not drive with VACC NOT OK 78 warning and the throttle released to neutral
Check throttle operation in the TESTER menu following page 48. The alarm sets when the accelerator reads 1.0 V above the required minimum with the control in neutral. Restart the system and make a new traction request. If the alarm returns while the throttle signal reads correct, replace the module.
Manual Section: Combi Module Node 2 Master Alarms p. 48Lift pump motor fault with PUMP VMN LOW 28 alarm and remote-control switch not closing
Check the pump motor internal connections for ohm continuity and inspect the power cable connections, per page 46. If the switch closes then opens immediately, test the motor phase windings and cables for leakage to the truck bodywork. Disconnect the battery before working on the electrical system (page 5). If the motor side checks good, replace the module.
Manual Section: Combi Module Node 2 Master Alarms p. 46Frequently Asked Questions
How do you troubleshoot a low-battery-voltage fault on a Hyster S-series electric truck?
If the battery charge is at or below 10%, the battery low alarm appears. You should charge the battery, then measure the voltage with a voltmeter and compare it to the VOLTAGE BATTERY parameter. If they do not match, adjust the ADJUST BATTERY function on the right connector, ensuring the pins are not interrupted. p. 48
What are the replacement specifications for a 24-V traction battery on the Hyster S1.0E, S1.2E, S2.4HBE?
The S1.0E and S1.2E models use a 24V/200Ah battery with a polypropylene container weighing 160 kg. Other options include a 24V/150Ah version weighing 144 kg or a 125 kg version with a polypropylene container. p. 21
What is the correct torque setting for the traction wheel retaining nuts on the Hyster S1.0E, S1.2E, S2.4HBE?
The traction wheel retaining nuts must be tightened using a torque wrench to a torque of 120 Nm. p. 173
How do you adjust the electromagnetic brake distance?
To obtain a good braking action, the distance between the friction disc and the brake plate must not be greater than 0.35 mm. Use a feeler gauge to set this distance by tightening the three retaining screws. p. 233
What is the required torque for the central lift cylinder bush on the Hyster S1.0E, S1.2E, S2.4HBE?
When installing the central lift cylinder, the bush must be tightened to 340 Nm. p. 154
Is this Hyster S1.0E manual a download or a disc?
One searchable PDF covering 241 pages, delivered instantly. No disc, no shipping, no waiting on the post.
Am I able to print pages from this Hyster S1.0E manual?
Yes. Many mechanics print the section they need for their own shop and bring it to the bench.
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